Strategic Expansion Into High-Value SteelProduction
An established steel producer in eastern China hascommissioned Primetals Technologies to execute a comprehensive upgrade of its1-strand continuous caster, marking a strategic pivot toward higher-value steelproducts. The project encompasses the supply and implementation of criticalmechanical equipment, alongside sophisticated Level 1 and Level 2 automationsolutions. This transformation will significantly expand the caster's thicknesscapability, reaching up to 360 millimeters, thereby enabling the manufacturerto penetrate the lucrative market for heavy-gauge, high-end applications. Thewind turbine sector, which demands exceptionally high-quality steel plates forstructural components, represents a particularly promising target market. Uponcompletion, the revamped facility will boast an annual production capacity of1.9 million metric tons of premium-grade slabs, with operations scheduled tocommence in mid-2026.
Cutting-Edge Technology Ensures SuperiorMetallurgical Quality
At the heart of thistechnological transformation lies Primetals Technologies' proprietarySingle-Roll DynaGap (SRD) segments, which represent a significant advancementin continuous casting technology. These sophisticated components enable dynamicalignment of individual casting gaps in response to fluctuations in criticalproduction parameters, including steel grade, cooling requirements, and castingspeed. The SRD segments can apply forces of up to 4,000 kilonewtons per roll,creating optimal conditions for superior internal microstructures. Thiscapability is particularly crucial for thick plate production, wheremaintaining consistent quality throughout the substantial cross-sectionpresents significant metallurgical challenges. The implementation of thistechnology ensures the production of defect-free, high-quality thick platesthat meet the exacting standards of premium applications.
Advanced Segment Design Revolutionizes SurfaceQuality
The upgrade incorporates Primetals Technologies' patentedSmart Segment concept, which implements continuous bending and straighteningthroughout the casting process. This innovative approach, combined withspecialized Eco Star rolls, delivers substantially improved slab-surfacequality, a critical factor for high-end applications where surfaceimperfections can compromise product integrity. The Eco Star rolls feature asophisticated internal cooling system that enables them to withstand theelevated temperatures necessary to minimize surface defects during the castingprocess. Additionally, the installation will include new Smart Molds equippedwith the DynaWidth mold-width adjustment system, providing operationalflexibility through fast and smooth slab-width changes. This combination oftechnologies addresses both the internal and external quality aspects of thecast product, ensuring comprehensive quality control.
Intelligent Automation Enhances Process Controland Product Consistency
The comprehensive automation solution being implementedrepresents a significant advancement in process control for continuous castingoperations. The sophisticated Mold Expert system serves as a technologicalsentinel, continuously monitoring conditions within the mold to detect andprevent potentially catastrophic breakouts while simultaneously analyzing thecasting process to optimize parameters in real-time. Complementing thiscapability, the automated DynaGap soft and hard reduction systems enable dynamicroll-gap control throughout the solidification process, effectively reducingcenterline segregation—a common metallurgical defect in thick slabs—andenhancing the internal quality of the cast strand. These intelligent systemswork in concert to ensure consistent product quality while providing theoperational flexibility needed to accommodate diverse product specifications.
Decades-Long Partnership UnderpinsTechnological Evolution
The collaboration between the Chinese steel producer andPrimetals Technologies represents the continuation of a long-standingtechnological partnership that spans decades and encompasses numerous castingprojects. This established relationship has facilitated a deep understanding ofthe producer's operational requirements and strategic objectives, enablingPrimetals Technologies to tailor the upgrade solution to address specificchallenges and opportunities. The longevity of this partnership reflects both thetechnical competence of Primetals Technologies in delivering successful castingsolutions and the producer's commitment to continuous technological advancementas a cornerstone of its competitive strategy in the evolving global steelmarket.
Strategic Positioning in High-Growth RenewableEnergy Sector
The timing of this investment aligns strategically with therapid expansion of renewable energy infrastructure, particularly in the windpower sector, which requires substantial quantities of high-quality steel platefor turbine towers and structural components. By enhancing its capability toproduce thick, high-quality slabs suitable for processing into premium plateproducts, the Chinese producer is positioning itself to capitalize on thegrowing demand driven by global decarbonization efforts. This market segmentoffers attractive margins compared to conventional steel products, providing apathway to improved profitability while contributing to the broader transitiontoward sustainable energy systems. The ability to manufacture steel suitablefor wind turbine applications represents not only a commercial opportunity butalso alignment with global sustainability imperatives.
Technological Integration Drives OperationalExcellence
The comprehensive nature of the upgrade, encompassing bothmechanical systems and advanced automation, reflects an integrated approach tomanufacturing excellence. Rather than addressing individual aspects of theproduction process in isolation, the project implements a holistic solutionthat optimizes the entire casting operation. The seamless integration ofmechanical equipment with sophisticated control systems ensures that thephysical capabilities of the caster are fully leveraged through precise, adaptiveprocess control. This approach maximizes both product quality and operationalefficiency, creating a sustainable competitive advantage. The implementation ofthese advanced technologies also enhances operational flexibility, enablingrapid adaptation to changing market demands and product specifications.
Environmental and Economic SustainabilityThrough Advanced Metallurgy
Beyond its commercial implications, the technologicalupgrade embodies the intersection of environmental and economic sustainabilityin modern steelmaking. The production of higher-quality steel products extendstheir service life and enhances performance in demanding applications,ultimately reducing material consumption over the lifecycle of end products.Additionally, the improved process control afforded by advanced automationsystems optimizes resource utilization during manufacturing, potentially reducingenergy consumption and associated carbon emissions. By focusing on high-valueproducts that command premium pricing while incorporating technologies thatenhance operational efficiency, the project exemplifies how technologicalinnovation can simultaneously address economic and environmental imperatives inheavy industry.
Key Takeaways:
• Primetals Technologies is upgrading a continuous casterfor an eastern Chinese steel producer to enable production of high-qualitythick slabs up to 360 millimeters, targeting premium applications includingwind turbines with an annual capacity of 1.9 million metric tons
• The installation features Single-Roll DynaGap segmentscapable of applying forces up to 4,000 kilonewtons per roll, alongside SmartSegment technology and Eco Star rolls to ensure superior internalmicrostructure and surface quality in thick plates
• Advanced automation systems including Mold Expert andautomated DynaGap reduction systems will provide real-time breakout prevention,process optimization, and quality control when the facility launches inmid-2026
